Pallet with a lifting strap

ABSTRACT

A pallet is described incorporating one or more lifting straps on an upper surface of the pallet. In one exemplary embodiment, a top surface of the pallet is substantially free from hand-sized or other similar orifices. In such embodiment, the at least one lifting strap provides a viable alternative to grasping the sides or edges of the pallet.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent Application No. 60/663,698, filed Mar. 18, 2005 and is a continuation-in part of U.S. patent application Ser. No. 10/729,615, filed Dec. 5, 2003, which is a divisional of U.S. patent application Ser. No. 09/938,954, filed Aug. 24, 2001, which claimed priority to U.S. Provisional Patent Application Ser. No. 60/227,537, filed Aug. 24, 2000, the entire contents of each of which are specifically incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to improvements in pallets, particularly those used for transporting miscellaneous industrial and commercial goods by means of forklift devices and the like.

BACKGROUND

Pallets are ordinarily moved about with fork lifting devices. In such use, forks of the forklift slip into openings beneath the pallet top deck and press upon an interior surface to raise the pallet from the floor.

However, occasionally it is useful to move pallets by hand. In order to grasp the pallet, a worker can reach into one of the forklift openings or into some other opening in the pallet, but sometimes that may not be convenient from the standpoint of accessibility. More significantly, a typical pallet for commercial use is about 40 by 48 inches by about 5 inches high, and weighs around 50 pounds.

Also, the deck of the pallet described by co-pending U.S. application Ser. No. 10/729,615, filed Dec. 5, 2003, to which the invention is well-applied (at least because it is not a conventional slatted design, but instead comprises a deck having few or no orifices suitable for use as hand holds), lacks the slats and openings of many wood pallets.

What is needed in the art is a plastic pallet, which pallet incorporates a deck design having few or no orifices suitable for use as handholds, that also incorporates a design permitting facile manual lifting and manipulation.

SUMMARY

The above described and other problems and disadvantages in the art are overcome or alleviated by the present pallet incorporating one or more lifting straps on an upper surface of the pallet. In one exemplary embodiment, a top surface of the pallet is substantially free from hand-sized or other similar orifices. In such embodiment, the at least one lifting strap provides a viable alternative to grasping the sides or edges of the pallet.

In another exemplary embodiment, at least one lifting strap is provided as part of the upper deck of the pallet. In another exemplary embodiment, the at least one lifting strap is provided in a valley of a corrugation in such a configuration that a substantial portion of the points of interface between the strap and the deck surface lies below the ridge of the corrugation.

The foregoing and other objects, features and advantages of the present pallet will become more apparent from the following description of exemplary embodiments and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the accompanying FIGURES, which are meant to be exemplary and not limiting:

FIG. 1 is a partial cutaway perspective view illustrating an exemplary corrugated deck incorporating a lifting strap within a corrugation valley; and

FIG. 2 is a partial cross sectional view of an exemplary strap, deck and column interface.

DETAILED DESCRIPTION

As noted above, the present disclosure relates to improvements in pallets, and in certain embodiments, plastic pallets. More particularly, the improvement described herein below provides a mechanism whereby the pallet may be more easily lifted and maneuvered by hand.

Referring now to FIG. 1, an exemplary pallet is illustrated generally at 20. The exemplary pallet 20 has a metal beam-reinforced plastic base, which base comprises a rectangular assembly of outer rails 44 connected by cross rails 44C. Eight molded plastic columns 42 run upwardly from the corners and midpoints of the base, to support a rectangular frame 24. A center column 42C (illustrated at the bottom of the partial illustration at FIG. 1) runs upwardly from the intersection of the cross rails 44C, in the middle of the pallet.

A corrugated aluminum deck 22 is attached to the frame 24 with fasteners 26, which in one exemplary embodiment are integrally molded plastic pins of the type described just below. Deck 22 is also pinned to the top of center column 42C by fasteners 34. In an exemplary embodiment, the deck 22 does not contain any holes or orifices that would accommodate a user's hand hold (for example, a slit wide enough and long enough to permit a user to insert four fingers there through and curl the four fingers against the deck or sub frame). In one exemplary embodiment, the deck does not contain any holes larger than about 3.5 inches long and 0.75 inches wide. In another exemplary embodiment, the deck does not contain any holes larger than about 4 inches long and 1 inch wide. In another exemplary embodiment, the deck does not contain any holes larger than a water drainage hole provided in a corrugation. It should be recognized that the above dimensions are merely exemplary.

Referring now to FIG. 2, lifting strap 30, is attached to the center column, as will be further described. However, before describing the lifting strap 30 and it's configuration relative to the pallet 20, it should be noted that the above described pallet and deck construction is merely exemplary. Though certain aspects of the above-construction may be beneficial, other types of construction would serve, so long as the lifting strap is secured to the reinforcing or structural components of the pallet.

Referring now to FIG. 2, a vertical cross section of the exemplary pallet of FIG. 1 is illustrated through the central part of the top of the pallet, along the length of bottom of a central diagonal valley corrugation 28 of deck 22. Exemplary column 42C has an interior hollow cavity 36, which in exemplary embodiments is filled with thermoset foam. While only one pin 34 is illustrated as attaching the deck to the center column 42C is shown, multiples may be used. In an exemplary embodiment, column 42C also has a corrugated surface which mates with the corrugations 28 of the deck 22 to more completely support it. In another exemplary embodiment, the pin 34 is molded as a post that is integral with the plastic of the column 42C. Assembly of the deck 22 and the post may be completed by positioning the deck in place with the post extending through a hole in the deck, followed by heating and deforming the post to the nominal shape of the pin 34, to thereby capture the deck in place.

Referring still to FIG. 2, exemplary lifting strap 30 is fastened to the pallet by means of two spaced apart strap-pins 32 which extend upwardly from the top of column 42C, and through clearance holes in the valley corrugation 28 of the deck 22. In an exemplary embodiment the pins 32 are plastic material integral to the column 42C, but they may have alternate configuration as described below.

In another embodiment, the pins 32 are formed in the same way as pins 34, with an exception. The pins 32 additionally pass through holes 38 of the strap 30. In another exemplary embodiment, the holes 38 in the strap 30 are oblong or rectangular. In such embodiment, the pins 32 may be configured such that the deformation of the top of the pin 32 is sufficient to capture the strap 30 and resist loads applied by the strap 30 during use, but insufficient to prevent lateral sliding motion of the strap 30, as indicated by arrows E, when the strap 30 is used to lift the pallet.

In another exemplary embodiment, and as illustrated in FIG. 2, the length of the strap 30 and the spacing between holes 38, relative to the spacing of pins 32, is selected so that the strap 30 cannot ever lie flat along the valley corrugation 28. That means there will always be some clearance underneath the strap. The upward curve of the strap enables a worker to readily grasp the strap with fingers. In another exemplary embodiment, the top 46 of the curved strap will be a distance D, for example about one-quarter inch, above the top of the peak corrugations 40 which lie on either side of the valley within which the strap is positioned, to make grabbing the strap even more convenient.

The strap may comprise any material and construction that will resist breaking under the weight of the pallet. In one exemplary embodiment, the strap comprises polypropylene or other flexible thermoplastic material, having a thickness of about one-eight inch. Thus, if there is another pallet or goods resting on the pallet at the strap location, or if things are push laterally across the deck, the strap will elastically deform and move downwardly into the valley, and it will then spring back up, when the contacting object is removed.

As noted above, in an exemplary embodiment the holes 38 may be oblong or rectangular, so when the pallet is lifted the strap curve will move, to extend upwardly higher than it is in its rest position, as is illustrated by FIG. 2, to thereby provide a larger space under the strap for the worker's hand. This feature lessens the necessary amount of extension of the top of the strap curve above the deck. While this feature may be beneficial, the strap may also be non-slidable along the deck. For example, the holes may be round, to fit the dimension of the pins 32, and a compromise curve and spacing underneath the strap will result.

Other configurations may also be implemented for fastening the strap 30 to the center column 42C (or indeed, to any other column, sub frame, or reinforcing or structural surface) or for fastening the deck 22 to the column 42C. For example, in an exemplary embodiment, metal screws or metal pins may be used instead of the integral deformed plastic pins. A lifting strap may also be at least partially secured to a side frame portion adjacent the deck.

Additionally, as noted above, other general pallet configurations are contemplated herein. In an exemplary embodiment, the deck is made of plastic rather than corrugated aluminum. Other corrugation patterns may be used, the deck may be smooth, or the deck may have other contouring. Also, while the above is described in terms of a center column, the strap may be applied to pallets with decks supported by other columns, or to non-column structures that will take and transfer the lifting load applied to the strap.

As described above, the present pallet incorporating a lifting strap enables workers to find a convenient place to grasp a pallet for lifting other than by grasping the pallet at its edges. This is advantageous because many workers do not find it easy to lift a pallet by grasping the openings along one edge or two adjacent edges. This is due to the fact that even a smaller span between opposing sides of a pallet (e.g., about 40 inches) is usually too large to enable a worker to easily grasp, lift and maneuver a pallet. The present improvement provides such ease of grasping, lifting and maneuvering of a pallet. 

1. A pallet, comprising: a deck; a sub frame connected to said deck; and a lifting strap secured to said sub frame and extending above the top surface of the pallet, wherein a portion of a lifting strap is spaced more than minimally above the top surface of the pallet so as to provide a handhold.
 2. A pallet in accordance with claim 1, wherein the deck is does not have a hole having a size that would serve to accommodate at least four human fingers.
 3. A pallet in accordance with claim 2, wherein the deck includes small drain holes there through.
 4. A pallet in accordance with claim 1, wherein the only other viable handhold is the side or side opening of said pallet.
 5. A pallet in accordance with claim 1, wherein the lifting strap is secured to the sub frame above a central portion of the deck.
 6. A pallet in accordance with claim 1, wherein the deck includes at least one corrugation, comprising a valley and a ridge.
 7. A pallet in accordance with claim 6, wherein the lifting strap is secured to the sub frame below a corrugation valley in the deck.
 8. A pallet in accordance with claim 7, wherein interfaces between the lifting strap and the sub frame are recessed within the corrugation valley of the deck and do not extend over the corrugation ridge of the deck.
 9. A pallet in accordance with claim 8, wherein the corrugation valley of the deck includes at least one drain hole.
 10. A pallet in accordance with claim 1, wherein the portion of the lifting strap that is secured to the sub frame includes an oblong or rectangular hole, through which a fastener extends connecting the lifting strap to the sub frame, and wherein the strap may slide under the fastener the length of the oblong or rectangular hole to adjust the distance between a portion of the strap and the top surface of the pallet.
 11. A pallet in accordance with claim 8, wherein a portion of the lifting strap extends above a corrugation ridge.
 12. A pallet in accordance with claim 11, wherein said portion extending above the corrugation ridge is elastically deformable, such that an object loaded thereon will press the portion of the lifting strap extending above the corrugation ridge into the corrugation valley.
 13. A pallet in accordance with claim 1, wherein the deck is metal.
 14. A pallet in accordance with claim 1, wherein the sub frame is at least partially plastic.
 15. A pallet in accordance with claim 14, wherein the sub frame is predominately plastic.
 16. A pallet in accordance with claim 5, wherein the lifting strap is secured to a central column of the subframe.
 17. A pallet, comprising: a corrugated metal deck; a plastic subframe, comprising lower outer rails connected to a rectangular outer frame portion by outer columns, and lower inner rails connected to said deck by at least one inner column; and at least one lifting strap fastened to said inner column.
 18. A pallet in accordance with claim 17, wherein the lifting strap is provided in a valley of a corrugation in the deck over said inner column.
 19. A pallet in accordance with claim 18, wherein the portion of the lifting strap that is secured to the inner column includes an oblong or rectangular hole, through which a fastener extends connecting the lifting strap to the sub frame, and wherein the strap may slide under the fastener the length of the oblong or rectangular hole to adjust the distance between a portion of the strap and the top surface of the deck.
 20. A pallet in accordance with claim 19, wherein a portion of the lifting strap extends above a corrugation ridge, and wherein said portion extending above the corrugation ridge is elastically deformable, such that an object loaded thereon will press the portion of the lifting strap extending above the corrugation ridge into the corrugation valley. 